MAINTENANCE SAFETY MANUAL

1 November 2012 704-0212-211 Revision AMAINTENANCE AND SAFETY MANUAL for VM Series Machining Centersii - MAINTENANCE and SAFETY Manual704-0212-211VM Series MAINTENANCE and SAFETY ManualThe information in this document is subject to change without notice and does not represent a commitment on the part of Hurco Companies, Inc. (Hurco). The software described in this document is furnished under the License Agreement to customers. It is against the law to copy the software on any medium except as specifically allowed in the license agreement. The purchaser may make copies of the software for backup purposes. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, for any purpose without the express written permission of the Hurco machine tool Manufacturing Company reserves the right to incorporate any modification or improvements in machines and machine specifications which it considers necessary, and does not assume any obligation to make any said changes in machines or equipment previously products and services are subject to Hurco s then current prices, terms, and conditions, which are subject to change without notice.

2 2012 Hurco Companies, Inc. All rights reserved. Patents B14,477,754; 5,453,933; Canadian Patent 1,102,434; Japanese Patents 1,649,006 and 1,375,124; other Patents , Max, Ultimax, and winmax are Registered Trademarks of Hurco Companies, , Autodesk, and DXF are registered trademarks of Autodesk, , Microsoft, and Windows are registered trademarks of Microsoft of the designations used by manufacturers and sellers to distinguish their products are claimed as trademarks. Hurco has listed here all trademarks of which it is aware. For more information about Hurco products and services, contact:Hurco Companies, Inc. One Technology Box 68180 Indianapolis, IN 46268-0180 Tel(317) 293-5309 (products)(317) 298-2635 (service)Fax (317) 328-2812 (service)For Hurco subsidiary contact information, go to Hurco s Web Series MAINTENANCE and SAFETY Manual704-0212-211VM MAINTENANCE Checklist iiiVM MAINTENANCE CHECKLISTD aily (Every 8 - 10 Hours) Perform operational checks.

3 4 - 2 Check the USB port.. 4 - 4 Check and maintain all lubricant levels.. 4 - 5 Clean the tool changer arm tool lock pins and tool gripper fingers.. 4- 10 Check the condition of tools.. 4- 11 Lubricate the non-motorized spindle taper.. 4- 12 Maintain the spindle chiller system (if equipped).. 4- 13 Check the spindle chiller (if equipped) working environment for appropriate ventilation and ambient temperature.. 4- 15 Check the FRL unit air pressure.. 4- 21 Check the auto moisture drain on FRL.. 4- 22 Check the coolant level.. 4- 24 Clean the chip conveyor tank (if equipped) chip screens.. 4- 26 Inspect the enclosure windows.. 4- 28 Check the Trunnion table (if equipped) clamping system s incoming pneumatic lines.

4 4- 29 Clean the Trunnion table (if equipped).. 4- 30 Check the rotary-axis oil level (if equipped).. 4- 30 Check the tilt-axis oil (if equipped).. 4- 31 Warm up the machine.. 4- 32 Weekly (Every 40 - 50 Hours) Clean the filter inside the heat exchanger.. 4 - 4 Check each tool holder.. 4- 11 Inspect the chiller solution level (if equipped), and if necessary, add solution to the unit.. 4- 13 Inspect the spindle chiller tank air filter and water filter (if equipped).. 4- 13 Clean the coolant filters.. 4- 24 Check the CTS coolant filter (if equipped) and clean when necessary.. 4- 25 Check the oil level for the clamping system (if equipped).. 4- 29 Monthly (Every 150-200 Hours) Inspect conduit, connectors, cabling, and external wiring.

5 4 - 4 Add a rust preventative to the Autolube system.. 4 - 6 Maintain the autolube fluid level and check the filler filter screen.. 4 - 7 Manually activate the Autolube system.. 4 - 8 Inspect limit switches and dog fasteners.. 4- 27 Perform a spindle run-in.. 4- 35Do not attempt to access the machine enclosure while machine power is on. Observe proper lock-out/tag-out procedures before performing any MAINTENANCE inside the machine - VM MAINTENANCE Checklist704-0212-211VM Series MAINTENANCE and SAFETY ManualEvery 3 Months (Every 500 Hours or as stated) Check the ATC oil level.. 4 - 9 Check the FRL air filter element regularly and replace it.. 4- 22 Drain moisture from the lines of the FRL.. 4- 22 Replace coolant and coolant filters.

6 4- 24 Replace the CTS coolant filter (if equipped).. 4- 25 Clean the chip conveyor tank (if equipped).. 4- 26 Measure the ground impedance (resistance to true earth).. 4- 28 Every 6 Months (Every 1000 Hours or as stated) Grease the ATC magazine chain assembly .. 4 - 9 Add grease to the Zerk fittings on the tool changer arm.. 4- 10 Verify the machine is sitting level.. 4- 28 Annually (Every 2000 Hours or as stated) Clean the autolube reservoir tank and suction filter.. 4 - 7 Replace the ATC oil.. 4 - 9 Flush, clean, and refill the spindle chiller tank (if equipped).. 4- 14 Replace the rotary-axis oil (if equipped).. 4- 30 Replace the tilt-axis oil (if equipped).. 4- 31VM Series MAINTENANCE and SAFETY Manual704-0212-211 Table of Contents vTABLE OF CONTENTSVM MAINTENANCE and SAFETY ManualVM MAINTENANCE Checklist.

7 IiiDocumentation Conventions .. ixMachine Standards .. 1 - 1CE Requirements .. 1 - 1 Declaration of Conformity .. 1 - 2 ANSI Standards .. 1 - 2 Machine Components .. 2 - 1 Overview .. 2 - 2 Machine Model Names .. 2 - 3 Frame .. 2 - 3 Enclosure .. 2 - 5 Spindle and Drive System .. 2 - 6 Axes Motion System .. 2 - 11 Machine Electrical Cabinet .. 2 - 14 Control Systems .. 2 - 21 Operator Control Console .. 2 - 21 Coolant System .. 2 - 26 Pneumatic System .. 2 - 27VM10G Dust Collector .. 2 - 27 Trunnion Table .. 2 - 28 Automatic Tool Changer .. 2 - 29 Operation Requirements .. 3 - 1 Machine Installation .. 3 - 2 Initial Test and Examination .. 3 - 5 Proper Operation and MAINTENANCE .

8 3 - 6 Machinery SAFETY .. 3 - 10 Noise Levels .. 3 - 13 Machine MAINTENANCE .. 4 - 1 Daily Operational Checks .. 4 - 2 USB Port .. 4 - 4 Heat Exchanger .. 4 - 4 Exterior Wiring .. 4 - 4 Lubrication .. 4 - 5 Pneumatic System .. 4 - 21 Flood Coolant and Washdown System .. 4 - 23 Chip Conveyor .. 4 - 26 Dust Collector VM10G .. 4 - 27 Limit Switches and Dogs .. 4 - 27 Machine Electrical Ground .. 4 - 28 Machine Level .. 4 - 28 Enclosure Windows .. 4 - 28 Trunnion Table .. 4 - 29 Machine Warm-up .. 4 - 32vi - List of Figures704-0212-211VM Series MAINTENANCE and SAFETY ManualSpindle Run-in or Cycle Procedure ..4 - 35 Troubleshooting ..4 - 38 Ordering Replacement Parts.

9 4 - 45 Record of Changes ..1 Index ..IX - 1 LIST OF FIGUREST able 2 1. VM Machine Table T-slot Specifications, Metric .. 2 - 3 Table 2 2. VM Machine Table T-slot Specifications, English .. 2 - 3 Table 2 3. VM Machine Table Specifications, Metric .. 2 - 4 Table 2 4. VM Machine Table Specifications, English .. 2 - 4 Table 2 5. VMX Machine Guideways .. 2 - 4 Table 2 6. Spindle Drive System Specifications, Metric .. 2 - 7 Table 2 7. Spindle Drive System Specifications, English .. 2 - 7 Table 2 8. Required Tool Holder Balance for VM10G Machine .. 2 - 8 Table 2 9. Recommended Tool Holder Specifications for VM10G .. 2 - 9 Table 2 10. Spindle Drive/Belt Ratio .. 2 - 10 Table 2 11. Axis Maximum Travel, Metric.

10 2 - 11 Table 2 12. Axis Maximum Travel, English .. 2 - 11 Table 2 13. Rapid Traverse Rates, Metric .. 2 - 12 Table 2 14. Rapid Traverse Rates, English .. 2 - 12 Table 2 15. Coolant Capacity and Pump Rating, Metric .. 2 - 26 Table 2 16. Coolant Capacity and Pump Rating, English .. 2 - 26 Table 2 17. Trunnion Table Maximum Allowable Workpiece Weight, Metric .. 2 - 28 Table 2 18. Trunnion Table Maximum Allowable Workpiece Weight, English .. 2 - 28 Table 2 19. ATC Tool Specifications, Metric .. 2 - 29 Table 2 20. ATC Tool Specifications, English .. 2 - 29 Table 4 1. Lubrication .. 4 - 5 Table 4 2. Differential Temperature Cooling process .. 4 - 16 Table 4 3. 6000 Max RPM Spindle Warm-up .. 4 - 32 Table 4 4. 8000 Max RPM Spindle Warm-up.